Badge for golf club head

ABSTRACT

The present disclosure concerns embodiments of a badge or insert for a golf club head that can eliminate undesired gaps between the insert and the peripheral sidewall of the cavity that receives the insert. In one embodiment, a golf club head comprises a main body comprising a cavity, which defines a central surface and an inner peripheral surface at least partially surrounding the central surface. An insert comprises a central portion and a deflectable portion coupled to and extending along a peripheral edge section of the central portion. The deflectable portion has a shape corresponding to and contacting a corresponding section of the inner peripheral surface of the cavity. The deflectable portion forms a press-fit engagement with the corresponding section of the inner peripheral surface of the cavity that retains the deflectable portion in a deflected state relative to the central portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent application Ser. No. 14/560,989, filed Dec. 4, 2014, which is a continuation of U.S. patent application Ser. No. 13/717,518, filed Dec. 17, 2012, now U.S. Pat. No. 8,920,261, both of which applications are incorporated herein by reference.

FIELD

The present disclosure concerns embodiments of a golf club head, and in particular, embodiments of an improved badge insert for a golf club head.

BACKGROUND

Iron-type golf club heads typically include large cavities in their rear surfaces. Typically, the position and overall size and shape of a cavity are selected to remove mass from that portion of the club head and/or to adjust the center of gravity of the club head. Manufacturers of golf clubs often place a badge or insert in the cavity for decorative purposes and/or for indicating the manufacturer name, logo, trademark, or the like. In addition, a badge or insert may be used to achieve a performance benefit, such as for vibration damping.

Due to variances in investment casting, the size of the cavity for any particular model can vary between different vendors that perform the casting process and between club heads supplied from the same vendor. As a result, badges are often designed to be undersized relative to the nominal size of the cavity so as not to interfere with the peripheral sidewall of the cavity and sometimes are installed offset toward one side of the cavity. Unfortunately, this leaves unsightly gaps around the periphery of the badge.

SUMMARY

The present disclosure concerns embodiments of a badge or insert that can eliminate undesired gaps between the insert and the peripheral sidewall of the cavity which can otherwise occur due to variances in the exact size of the cavity. The insert typically is installed in the rear surface of an iron-type golf club head. Accordingly, the detailed description that follows describes embodiments of an insert installed in the rear surface of an iron-type club head. However, the insert also can be installed in a cavity formed in another portion of the club head (such as the front, heel, toe, upper, and/or lower portions of the club head) or in another type of club head (such as a driver or wood-type club head, a putter or wedge).

In one representative embodiment, a golf club head comprises a body comprising a face portion defining a striking face of the club head and a rear portion opposite the face portion. The rear portion includes a cavity, which defines a rear inner surface substantially opposite the striking face and an inner peripheral surface at least partially surrounding the rear inner surface. An insert is disposed in the cavity. The insert comprises a central portion and a peripheral edge portion coupled to the central portion. At least a portion of the peripheral edge portion comprises a deflectable portion having a shape corresponding to and contacting a corresponding section of the inner peripheral surface of the cavity, with the deflectable portion being retained in a deflected state by contact with the corresponding section of the inner peripheral surface of the cavity.

In another representative embodiment, a golf club head comprises a main body comprising a cavity, which defines a central surface and an inner peripheral surface at least partially surrounding the central surface. An insert is disposed in the cavity. The insert comprises a central portion and a deflectable portion coupled to and extending along a peripheral edge section of the central portion. The deflectable portion has a shape corresponding to and contacting a corresponding section of the inner peripheral surface of the cavity. The deflectable portion forms a press-fit engagement with the corresponding section of the inner peripheral surface of the cavity that retains the deflectable portion in a deflected state relative to the central portion.

In another representative embodiment, a method of assembling a golf club head comprises providing a golf club head comprising a face portion defining a striking face of the club head and a rear portion opposite the face portion, the rear portion including a cavity, the cavity defining a rear inner surface substantially opposite the striking face and an inner peripheral surface at least partially surrounding the rear inner surface. The method further comprises providing an insert comprising a central portion and a deflectable portion at least partially surrounding the central portion and corresponding to the shape of a corresponding section of the inner peripheral surface of the cavity, the deflectable portion being in a non-deflected state that is larger than the corresponding section of the inner peripheral surface. The insert is then inserted into the cavity such that the deflectable portion contacts the corresponding section of the inner peripheral surface of the cavity and moves to a deflected state relative to the central portion.

The foregoing and other objects, features, and advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary embodiment of an iron-type golf club head having an insert installed in the rear portion of the club head.

FIG. 2 is a cross-sectional view of the club head taken along line 2-2 of FIG. 1.

FIG. 3 is a perspective, exploded view of the club head and the insert of FIG. 1.

FIG. 4 is a rear elevation view of the club head of FIG. 1, shown with the insert removed for purposes of illustration.

FIG. 5 is an elevation view of the insert of FIG. 1, shown apart from the club head.

FIG. 6 is a cross-sectional view of a club head having another embodiment of an insert installed in the rear portion of the club head.

FIG. 7 is an elevation view of the insert of FIG. 6, shown apart from the club head.

FIG. 8 is a cross-sectional view of the insert taken along line 8-8 of FIG. 7.

DETAILED DESCRIPTION

Referring first to FIGS. 1-4, there is shown an iron-type golf club head 10, according to one embodiment. The club head 10 comprises a main body 12 having an upper portion 14, a lower portion 16, a toe portion 18, a heel portion 20, and a hosel 22 extending from the area where the heel portion 20 joins the upper portion 14. A shaft 24 can be joined to the hosel 22 to form an assembled golf club. The lower end portion of the shaft 24 extends into the hosel 22 and is secured in place relative to the main body 12 using conventional techniques or mechanisms.

The main body 12 also includes a face portion 26 defining a front striking face 28 for the club head and a rear portion 30 opposite the face portion 26. The rear portion 30 includes a recessed portion, or cavity, 32. As best shown in FIG. 3, the cavity 32 has a main inner surface 44 and an inner peripheral surface 46 surrounding the main inner surface. Disposed inside the cavity 32 is an insert 34 (also referred to as a “badge,” “badge insert,” or “medallion”). The insert 34 has an exposed outer surface 36 that is visible to a user. Words, logos, designs, graphics, trademarks, and other types of visible indicia may be printed or formed on the outer surface 36 for aesthetic or decorative purposes. In some embodiments, the insert 34 may also comprise materials or be constructed in a manner to provide a performance benefit, such as vibration damping.

In the illustrated embodiment, as best shown in FIG. 2, a lower portion 48 of the cavity 32 is formed between the face portion 26 and a lower rear portion 50 of the club head. Thus, as can be seen, the insert 34 can be sized such that it extends slightly below an upper ledge 52 of the lower rear portion 50. As shown in FIG. 2, there can be a substantial gap between the inner peripheral surface 46 and the insert 34 within the lower cavity portion 48. The insert 34 need not be sized to cover this gap since it is hidden from view by the lower rear portion 50.

Referring to FIG. 5, the insert 34 comprises a central portion 38 and an outer peripheral portion 40 coupled to and extending along the peripheral edge of the central portion 38. At least a portion of the peripheral portion 40 of the insert comprises a deflectable portion 42 that has a shape corresponding to and contacting a corresponding section 56 of the inner peripheral surface 46 of the cavity 32. In the illustrated embodiment, the deflectable portion 42 comprises the extent of the peripheral portion 40 encircled by dashed line 54 (FIG. 5) and the corresponding section 56 of the inner peripheral surface 46 comprises the extent of the peripheral surface 46 encircled by dashed line 58. As can be seen, the deflectable portion 42 extends along the peripheral upper edge and the peripheral heel and toe edges of the central portion but not along the peripheral lower edge of the central portion. Thus, in the illustrated embodiment, the lower part of the peripheral portion 40 that extends into the lower cavity portion 48 (and which is mostly hidden from view), need not be part of the deflectable portion because it is spaced from the peripheral inner surface 46 within the lower cavity portion 48 (FIG. 2).

The deflectable portion 42 is configured to be slightly oversized relative to the corresponding section 56 of the inner peripheral surface 46 but is deflectable relative to the central portion 38 to allow the deflectable portion 42 to conform to the corresponding section 56 as the insert is press-fitted into the cavity. In this manner, the deflectable portion 42 can contact the corresponding section 56 continuously along the entire extent of the deflectable portion 42 so that there are no visible gaps between the deflectable portion and the inner peripheral surface 46 of the cavity. Thus, if the exact size of the cavity for a particular model varies between club heads, such as due to investment casting variances or other manufacturing limitations, the insert 34 can be installed in the cavity without any visible gaps.

As shown in FIG. 2, an inner surface 68 of the insert can be adhesively secured to the inner surface 44 of the cavity, such as with a layer of double-sided tape 60, to ensure that insert remains in place within the cavity during normal use of the golf club. Alternatively, the insert 34 can be secured to the inner surface 44 of the cavity with epoxy or another suitable adhesive or glue.

As best shown in FIG. 2, the deflectable portion 42 in the illustrated configuration is coupled to the peripheral edge of the central portion 38 by a living hinge 62. The hinge 62 allows the deflectable portion 42 to conform to the inner peripheral surface 46 when the insert is pressed into the cavity 32. The hinge 62 can be formed by machining, injection molding, or otherwise forming a thinned region to reduce the cross-sectional thickness of the insert at or near the location at which the peripheral edge of the central portion 38 is coupled to the living hinge 62, such as a V-shaped gap 64 along the outer peripheral surface of the insert. In particular embodiments, the insert 34 can be a unitary piece of material that is molded, cast, machined or otherwise formed to have a central portion 38 and a raised peripheral portion 40 having a thickness greater than the central portion. The peripheral portion 40 (or at least the portion that will form the deflectable portion 42) is formed such that it is slightly larger than the opening defined by the corresponding section 56 of the inner peripheral surface. The gap 64 can then be formed in the outer peripheral surface of the insert to form the deflectable portion 42 and the hinge 62. The outer peripheral edge 66 of the central portion can be formed, or trimmed (if needed) so that it can fit within the cavity without contacting the inner peripheral surface. In the illustrated embodiment, the gap 64 is not formed in the portion of the insert 34 that extends into the lower cavity portion 48. Thus, the lower peripheral portion 40 of the insert that extends into the lower cavity portion 48 is simply defined by a raised portion of the insert. However, in other embodiments, the entire extent of the peripheral portion 40 can be a deflectable portion 42 (i.e., the hinge 62 can extend completely around the outer peripheral surface of the insert).

When the insert 34 is apart from the club head 10, the deflectable portion 42 is in a non-deflected state having a larger peripheral shape than the opening defined by the corresponding section 56 of the cavity. When the insert 34 is pressed into the cavity, the deflectable portion 42 contacts the corresponding section 56 of the inner peripheral surface 46 and is deflected inwardly slightly relative to the central portion 38 to assume a deflected state while the central portion 38 is not deformed or deflected by the installation process.

Any of various suitable materials can be used to form the central portion 38 and the peripheral portion 40. For example, in some embodiments, the central portion 38 may comprise a metal (e.g., aluminum, steel, nickel, cobalt, titanium, or alloys including these materials) and/or one or more of various polymers (e.g., ABS plastic (acrylonitrile-butadiene-styrene), nylon, and/or polycarbonate). In some embodiments, the peripheral portion 40 may comprise a metal (e.g., aluminum, nickel, cobalt, steel, titanium, or alloys including these materials), one or more of various polymers (e.g., ABS plastic, nylon, polycarbonate, or combinations of these materials), and/or an elastomer or a viscoelastic material, such as rubber or any of various synthetic elastomers, such as polyurethane, a thermoplastic or thermoset material polymer, or silicone or combinations of these materials.

In alternative embodiments, the entire cavity 32 may be visible, or it may be otherwise preferable to provide an insert 34 that is coextensive with the entire cavity 32. In such cases, the deflectable portion 42 can comprise the entire extent of the peripheral portion 40, such that the deflectable portion 42 contacts the entire inner peripheral surface 46, thereby eliminating any gaps between the insert and the inner peripheral surface 46 of the cavity.

FIGS. 6-8 illustrate an insert 100, according to another embodiment, installed within the cavity 32 of the club head. The insert 100 comprises a central portion 102 and a deflectable peripheral portion 104 surrounding the outer peripheral edge of the central portion 102. The central portion 102 comprises an outer, exposed surface 106 on which there can be provided various indicia, logos, designs, and the like. The insert has an inner surface 108 that can be secured to the inner surface 44 of the cavity, such as with a piece of double-sided tape 110 or a suitable adhesive, such as epoxy.

The central portion 102 comprises a first material (or a first combination of multiple materials) and the peripheral portion 104 comprises a second material that is relatively more pliable and/or deformable than the first material. Like the insert 34 described above, the peripheral portion 104 of insert 100 corresponds to and contacts a corresponding section 56 of the inner peripheral surface 46 of the cavity. When the insert 100 is apart from club head 10, the peripheral portion 104 is in a non-deformed, non-deflected state that is slightly larger than the opening defined by the corresponding section 56 of the inner peripheral surface 46 of the cavity. When pressed into the cavity, the peripheral portion 104 can conform to the inner peripheral surface 46 and can contact the inner peripheral surface 46 continuously along the entire extent of the corresponding section 56 without any visible gaps between the peripheral portion 104 and the corresponding section 56. In other words, the peripheral portion 104 that comes in contact with the corresponding section 56 of the inner peripheral surface 46 moves to a deformed or deflected state in continuous contact with that portion of the inner peripheral surface 46 while the central portion 102 is not deflected or deformed by the installation process.

In particular embodiments, the peripheral portion 104 is formed from an elastomer or a viscoelastic material, such as rubber or any of various synthetic elastomers, such as polyurethane, a thermoplastic or thermoset material polymer, or silicone. The central portion 102 is formed from a material that is firmer than the peripheral portion 104. Desirably, the material for the central portion 102 is selected such that the central portion 102 does not deflect or deform when the insert 100 is inserted into the cavity 32. In particular embodiments, for example, the central portion can be formed from any suitable metal (such as aluminum, steel, nickel, cobalt, titanium, or alloys including these materials) or a polymer that is relatively harder than the material used to form the peripheral portion. For example, relatively harder polymers that can be used to form the central portion 102 include ABS plastic, nylon, and/or polycarbonate.

The peripheral portion 104 can be joined to the central portion 102 using any of various suitable techniques or mechanisms. For example, the peripheral portion 104 can be co-molded with and/or around the central portion 102. Alternatively, the peripheral portion 104 can be joined to the central portion 102 using an adhesive, welding, or by an interference fit between the two components.

In the illustrated embodiment, the entire peripheral portion 104 is deflectable, although this not need be the case. Since the lower part of the insert 100 extends into the lower cavity portion 48 and does not contact the adjacent portion of peripheral surface 46 (as shown in FIG. 6), this part of the insert need not include a deflectable peripheral portion. Of course, in embodiments where the entire cavity in the rear of the club head is visible, or where it may be otherwise preferable to provide an insert 100 that is coextensive with the entire cavity 32, it would be beneficial to provide a deflectable peripheral portion around the entire periphery of the insert.

The disclosed embodiments can be adapted for inserts that are installed in cavities and/or pockets located in other portions of a club head and for inserts that are installed in club heads other than irons, such as wood-type club heads (e.g., drivers), putters and wedges. In certain embodiments, for example, an insert having a deformable or deflectable peripheral portion as discussed above can be installed in a cavity located at any portion of any type of club head (e.g., a cavity formed in the upper portion, the lower portion, the toe portion, the heel portion, the rear portion, and/or the front portion of a club head). In one specific implementation, an insert having a deformable or deflectable peripheral portion in installed in the front face portion of a club head and forms the striking surface of the club head.

Furthermore, inserts as disclosed herein can also be adapted to be installed in products other than golf club heads, such as various types of sporting goods, household appliances, machinery, to name just a few. Thus, the embodiments of inserts disclosed herein can be installed in a cavity that is formed in just about any product or device.

General Considerations

For purposes of this description, certain aspects, advantages, and novel features of the embodiments of this disclosure are described herein. The disclosed methods, apparatuses, and systems should not be construed as limiting in any way. Instead, the present disclosure is directed toward all novel and nonobvious features and aspects of the various disclosed embodiments, alone and in various combinations and sub-combinations with one another. The methods, apparatuses, and systems are not limited to any specific aspect or feature or combination thereof, nor do the disclosed embodiments require that any one or more specific advantages be present or problems be solved.

Although the operations of some of the disclosed methods are described in a particular, sequential order for convenient presentation, it should be understood that this manner of description encompasses rearrangement, unless a particular ordering is required by specific language. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed methods can be used in conjunction with other methods. As used herein, the terms “a”, “an” and “at least one” encompass one or more of the specified element. That is, if two of a particular element are present, one of these elements is also present and thus “an” element is present. The terms “a plurality of” and “plural” mean two or more of the specified element.

As used herein, the term “and/or” used between the last two of a list of elements means any one or more of the listed elements. For example, the phrase “A, B, and/or C” means “A,” “B,” “C,” “A and B,” “A and C,” “B and C” or “A, B and C.”

As used herein, the term “coupled” generally means physically coupled or linked and does not exclude the presence of intermediate elements between the coupled items absent specific contrary language.

In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only preferred examples of the invention and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims. We therefore claim as our invention all that comes within the scope and spirit of these claims. 

We claim:
 1. A golf club head comprising: a body comprising a face portion defining a striking face of the club head and a rear portion opposite the face portion, the rear portion including a cavity, the cavity defining a rear inner surface substantially opposite the striking face and an inner peripheral surface at least partially surrounding the rear inner surface, wherein the cavity comprises an upper portion and a lower portion, the lower portion of the cavity being formed between the face portion and a lower wall of the rear portion having an upper ledge; and an insert disposed in the cavity, the insert comprising a central portion and a peripheral edge portion coupled to the central portion, the peripheral edge portion comprising an upper, deflectable portion having a shape corresponding to and contacting a corresponding section of the inner peripheral surface of the upper portion of the cavity, the deflectable portion being retained in a deflected state by contact with the corresponding section of the inner peripheral surface of the upper portion of the cavity, the peripheral edge portion further comprising a lower portion that extends below the upper ledge and partially into the lower portion of the cavity and is spaced from a corresponding section of the inner peripheral surface of the lower portion of the cavity such that an empty space is defined between the lower portion of the peripheral edge portion and the corresponding section of the inner peripheral surface of the lower portion of the cavity.
 2. The golf club head of claim 1, wherein the upper deflectable portion contacts an entire extent of the inner peripheral surface of the upper portion of the cavity above the upper ledge.
 3. The golf club head of claim 2, wherein the lower portion of the peripheral edge portion is in a non-deflected state.
 4. The golf club head of claim 1, wherein the central portion has an inner surface that is adhesively secured to the rear inner surface of the cavity.
 5. The golf club head of claim 1, wherein the upper deflectable portion is coupled to the central portion of the insert with a hinged connection.
 6. The golf club head of claim 5, wherein the hinged connection comprises a living hinge.
 7. The golf club head of claim 5, wherein the hinged connection comprises a notch formed in the insert.
 8. The golf club head of claim 5, wherein the hinged connection extends along a peripheral upper edge of the central portion and peripheral heel and toe edges of the central portion.
 9. The golf club head of claim 1, wherein the upper deflectable portion comprises an elastomer that is elastically deformed into the deflected state by contact with the corresponding section of the inner peripheral surface of the upper portion of the cavity.
 10. The golf club head of claim 9, wherein the central portion comprises a material that is relatively harder than the elastomer.
 11. A golf club head comprising: a main body comprising a cavity in an external surface thereof, the cavity defining a central surface and an inner peripheral surface at least partially surrounding the central surface; and an insert disposed in the cavity and visible during use of the golf club head, the insert comprising a central portion and a deflectable portion coupled to the central portion with a hinged connection, the deflectable portion having a shape corresponding to and contacting a corresponding section of the inner peripheral surface of the cavity, the deflectable portion engaging with the corresponding section of the inner peripheral surface of the cavity, the engagement of the deflectable portion with the corresponding section of the inner peripheral surface of the cavity causing the deflectable portion to bend relative to the central portion at the hinged connection to a deflected shape and retaining the deflected shape of the deflectable portion; wherein the hinged connection extends along a peripheral upper edge of the central portion and peripheral heel and toe edges of the central portion.
 12. The golf club head of claim 11, wherein the hinged connection comprises a living hinge.
 13. The golf club head of claim 11, wherein the hinged connection comprises a notch formed in the insert.
 14. The golf club head of claim 11, wherein the hinged connection extends from one end of a peripheral lower edge of the central portion, along the peripheral heel edge of the central portion, along the peripheral upper edge of the central portion, and along the peripheral toe edge of the central portion to another end of the peripheral lower edge of the central portion. 